JBA 1962S Installation Instructions Manual

Brand: JBA

Model: 1962S

Type: Installation Instructions Manual

JBA 1962S, the best fitting header on the market, enhances the performance of your 2004-2005 Dodge Durango 5.7 HEMI, giving you a thrilling driving experience. Its ceramic coating offers protection against extreme heat, ensuring durability. Installation is straightforward, but remember to follow the instructions carefully for optimal results. Experience the power and precision of JBA 1962S headers, designed to unleash the true potential of your vehicle.

Installation Instructions

and Warranty Information

1962S 2004-08 Dodge Durango 5.7 HEMI

Read all instructions carefully before attempting installation.

Rev.1 2-28-13

Corporate Ofce: PerTronix Inc. 440 E. Arrow Highway, San Dimas, California 91773 * Phone 909.599.5955 • FAX 909.599.6424



2004-2005 ONLY!

PerTronix© thanks you for choosing JBA HEADERS, the best ﬁtting, highest quality

header on the market. In order to realize the full potential of our good ﬁt, please read and

understand these instructions completely prior to starting work.

Check to make sure you received the proper parts for your application. The header num-

ber will be stamped on the engine ﬂange. If you are unsure you have received the proper

parts call before you start work.

Be sure to work safe! Whenever you work under the vehicle be sure that it is located on

level, solid ground and is supported by adequate safety stands! Remember: Hot asphalt

will not support most jack stands!

Many factors affect the installation of headers, some of which are broken or aftermarket

motor mounts, accidents that impact the conﬁguration of the frame, and/or the installation

of different engines or aftermarket cylinder heads.

Attention Customers breaking in new engines: Due to the extreme heat generated dur-

ing the break-in process, the appearance of the ceramic coating may be altered in certain

areas. The protection characteristics and thermal barrier properties of the coating is never

compromised. It is recommended that a cast iron manifold or old set of headers be used

for this process.

Notice: The coating of these headers can be marred or scratched during installation. If the

header needs to be returned and is damaged, you will be charged for recoat.

JBA uses sealing beads on all its headers. We have found that when installed correctly, the

raised bead around each port increases the pressure exerted on the gasket directly adjacent to

the port and effectively prevents leaking gaskets. It is normal for the ﬂange to be raised off the

cylinder head the thickness of the sealing bead. It is important when installing the header, to in-

stall all bolts loosely, then tighten evenly to ensure the ﬂat installation of the ﬂange. The torque

sequence from one ﬂange to another will vary, but generally every bolt on a header should be

ﬁrst ﬁt snug, starting from the inside of the ﬂange working out, alternating from top to bottom

so that the bolt connects the ﬂange to the manifold to the point where they barely touch. Sec-

ond, using the same inside-out pattern, tighten each bolt until ﬁnished. This method will help

prevent leakage and will give the user the best possible performance out of their pair of headers.

1. Place vehicle in a location where the ﬂoor is solid and ﬂat, with adequate lighting. Do not attempt to work

on a hot engine. Heat causes metal to expand and makes removal of fasteners difﬁcult at best. Disconnect the

battery cables from the battery. Raise the front of the vehicle to obtain adequate access to the bottom exhaust

manifold ﬂanges. Use large-base jack stands to support the vehicle. Do not rely on the jack! Block the tires to

prevent the vehicle from rolling off the jack stands.

2. Spray WD-40 or some type of penetrating oil on all accessible fasteners and ﬁttings before attempting to

remove them.

Note: It is recommended that you work on one side at a time.

3. Cut the front exhaust pipes in front of the catalytic converters, just in front of the weld.

4. Unplug the front O2 sensors. Then unbolt the front exhaust pipes and remove them.

5. Remove the four nuts attaching the heat shields to the manifolds. Then remove the shields.

6. Unbolt and remove the manifolds.

7. Using a wire brush or scraper, carefully clean carbon deposits from head. (Use care not to gouge the head

surface.)

8. Relocate transmission cable on the driver’s side by unbolting bracket

from starter bolt. Reinstall starter bolt. Flip the bracket so the front be-

comes the back, and the top becomes the bottom. Move the bracket to the

lower open hole on the bell housing. Attach the bracket using the hard-

ware provided. (See picture)

9. Install the new JBA Headers using the hardware and gaskets provided.

Adjust transmission cable bracket to gain maximum clearance from

header.

10. Install new exhaust connector pipes using hardware provided. Align

with cat converter, tack weld. Check to insure adequate clearance on ﬂoor,

torsion bars, trans lines etc.

11. Weld pipes completely.

12. Transfer O2 sensors to new pipes, and reconnect connectors.

13. Check headers to insure adequate clearance on battery cables,wire looms,coolant lines,etc.

14. Reconnect battery cables.

15. Recheck everything.

16. Start engine,check for leaks.

17. We recommend that you re-torque the fasteners on the headers after approximately 100 miles of driving. All

tubular headers require maintenance including periodically checking and retightening of the header bolts.

LIMITED ONE YEAR WARRANTY

All JBA HEADERS and exhaust products are guaranteed, to the original purchas-

er, to be free of defects in materials and workmanship for one year. This warranty

covers the replacement or repair of the product only and does not cover the cost

of removal and installation, customer applied aftermarket coatings or any discolor-

ation or corrosion of nished surfaces.

Damage or product failure resulting from collision, improper installation, off-road

use, road hazards, the use of exhaust insulating wrap or like products or rust oc-

curring after installation, is not covered by the warranty. The warranty extends only

to the original purchaser.

Should a part become defective it should be returned to the original selling retailer

and must be accompanied with the sales receipt. If there is no retailer in your area,

call the factory for a return authorization and return your part prepaid to the factory

for inspection. PerTronix reserves the rights to replace or repair the alleged defec-

tive part and return the part freight collect.

Parts List:

(1) Driver ’s Side Header Assembly (6) 3/8 x 2-1/2 bolts with washers and nuts

(1) Passenger ’s Side Header Assembly (1) 3/8 x 1 1.2 bolt w/washers and nut

(2) Head ﬂange Gaskets (1) Driver side down tube

(17) 8mm -bolts with lock washers (1) Passenger side down tube

Applicable to 2004-2005 vehicles ONLY!

JBA 1962S Installation Instructions Manual

JBA 1962S Installation Instructions Manual

JBA 1962S Installation Instructions Manual

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